Indirect cooling of the cutting tool with a pumped two-phase system in turning of AISI 1045 steel

Neto, Rubens Roberto Ingraci; Scalon, Vicente Luiz; Fiocchi, Arthur Alves; Sanchez, Luiz Eduardo de Ângelo

doi:10.1007/s00170-016-8620-6

Cited by 14 publications

(25 citation statements)

References 36 publications

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“…Micro-manufacturing operations produce heat as a by-product of machine use [2]. In precision machining applications, the excess tool wear due to the heat induced during cutting actions is a major challenge in thermal management [3,4]. The necessity for a cooling mechanism in machining operations has been well documented [4][5][6].…”

Section: Need For Heat Reduction In Mechanical Cutting Processesmentioning

confidence: 99%

“…In precision machining applications, the excess tool wear due to the heat induced during cutting actions is a major challenge in thermal management [3,4]. The necessity for a cooling mechanism in machining operations has been well documented [4][5][6]. Cooling, either by external or internal approaches, helps reduce tool wear and improve thermal degradation, which affects the surface integrity of workpieces [6,7].…”

Section: Need For Heat Reduction In Mechanical Cutting Processesmentioning

confidence: 99%

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Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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The effective removal of the heat generated during mechanical cutting processes is crucial to enhancing tool life and producing workpieces with superior surface finish. The internal cooling systems used in cutting inserts employ a liquid water-based solvent as the primary medium to transport the excess thermal energy generated during the cutting process. The limitations of this approach are the low thermal conductivity of water and the need for a mechanical input to circulate the coolant around the inner chamber of the cutting tool. In this context, this paper proposes an alternative method in which liquid gallium is used as the coolant in combination with a magnetohydrodynamic (MHD) pump, which avoids the need for an external power source. Using computational fluid dynamics, we created a numerical model of an internal cooling system and then solved it under conditions in which a magnetic field was applied to the liquid metal. This was followed by a simulation study performed to evaluate the effectiveness of liquid gallium over liquid water. The results of experiments conducted under non-cooling and liquid gallium cooling conditions were analyzed and compared in terms of the tool wear rate. The results showed that after six machining cycles at a cutting speed Vc = 250 m min −1, the corner wear VBc rate was 75 µm with the coolant off and 48 µm with the MHD-based coolant on, representing a decrease of 36% in tool wear. At Vc = 900 m min−1, the corner wear VBc rate was 75 µm with the coolant off and 246 µm with the MHD-based coolant on, representing a decrease of 31% in tool wear. When external cooling using liquid water was added, the results showed at Vc = 250 m min−1, the difference between the tool wear rate reduction with the internal liquid gallium coolant relative to the external coolant was 29%. When the cutting speed was increased to Vc = 900 m min−1, the difference observed between the internal liquid gallium coolant relative to the external coolant was 16%. The study proves the feasibility of using liquid gallium as a coolant to effectively remove thermal energy through internally fabricated cooling channels in cutting inserts.

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Section: Need For Heat Reduction In Mechanical Cutting Processesmentioning

confidence: 99%

Section: Need For Heat Reduction In Mechanical Cutting Processesmentioning

confidence: 99%

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

O’Hara,

Fang

2023

Nanomanuf Metrol

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“…The sustainability indicators studied in the articles were codified and extracted, and key indicators were identified for each TBL sustainability dimension, as presented in Fig- Cutting environment was evidenced as the key theme of the latest sustainable machining body of knowledge (70% of articles categorised under sustainable machining), with SM technology studies studying the elimination of lubrication substances through cryogenic [138,139], dry machining [128,140] and indirect cooling [141], or their reduction/optimisation through minimum quantity lubrication (MQL) techniques [142,143].…”

Section: Sustainability Indicators Studiedmentioning

confidence: 99%

Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

Bastas

2021

Sustainability

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Meeting current needs while not sacrificing the future ability to do so as a key sustainability concept is becoming more challenging than ever, with the increasing population rate, energy poverty, global warming, and surging demand for products and services. Manufacturing is in a prime position to address this challenge, with its significant economic contribution to the global GDP and its high influence over the environment and humanity. Sustainable manufacturing technologies research is growing to support our journey towards sustainable development. This article undertook the systematic review of state-of-the-art sustainable manufacturing technologies literature, evidencing the latest themes and trends in this important research avenue. Descriptive and thematic analyses were performed, synthesising the latest advancements in the field. Sustainable manufacturing processes, especially sustainable machining, was established as a key theme, including research endeavours of elimination of lubricants. Various manufacturing systems and process sustainability assessment technologies were noted. Sustainability indicators addressed were critically evaluated. As an outcome, a conceptual framework of sustainable manufacturing technology research was constructed to structure the knowledge acquired and to provoke future thinking. Finally, challenges and future directions were provided for both industrial and academic reader base, stimulating growth in this fruitful research stream.

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“…The potential to employ internal cooling to reduce heat within the cutting tool is drawing the attention of researchers [ 5 , 8 – 10 ]. The ability to machine without the use of external liquids, in particular flooding techniques, suggests that dry machining in combination with internal cooling, is an enabling technology which has the potential to realise environmentally friendly machining in industrial applications [ 5 ].…”

Section: Introductionmentioning

confidence: 99%

“…Neto et al [ 8 ], employed a two-phase pump cooling system in a closed loop design whereby the circulating liquid water vaporises upon contact with a silver interface that acts to cool the cutting tool during machining. Condensing of the vaporised liquid occurred through forced convection at 25 °C, and then was mechanically pumped back at a feed rate of 1.78 min −1 into the internal channel system.…”

Section: Introductionmentioning

confidence: 99%

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

O’Hara,

Fang

2024

Int J Adv Manuf Technol

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One of the challenges in the transfer of heat during the mechanical machining process is the coolant substance used in the internal cooling method which is generally liquid water or a water-based coolant. This limits the heat transfer capacity insofar as the thermal conductivity of liquid water is concerned. The other difficulty is the requirement for an external mechanical system to pump the coolant around the internal channel, providing efficient transfer of the accumulated thermal energy. This study proposes a novel method to address this issue by using liquid gallium which provides the means to transfer the excess heat generated during the cutting process by integrating the design into an aluminium oxide insert. Combining this with a magnetohydrodynamic drive, the coolant system operates without the need for mechanical input. Liquid gallium is nontoxic and has a much higher thermal conductivity over liquid water. Investigations of the novel cooling system is performance compared against liquid water through numerical modelling, followed by an experimental machining test to ascertain the difference in heat transfer effectiveness, tool wear rates and workpiece surface finish when compared to dry machining and external cooling conditions on stainless steel 316L. Without cooling, experimental machining tests employing a cutting speed of Vc = 250 m min−1 resulted in a corner wear VBc rate of 75 μm, and with the magnetohydrodynamic-based coolant on, produced a VBc rate of 48 μm, indicating a difference of 36% in relative tool wear under the same cutting conditions. Increasing the cutting speed Vc to 900 m min−1, produced a corner wear VBc rate of 357 μm without the active coolant and a VBc rate of 246 μm with the magnetohydrodynamic-based coolant on, representing a decrease of 31% in relative tool wear. Further tests comparing external liquid water cooling against the liquid gallium coolant showed at Vc = 250 m min−1, a difference of 29% in relative tool wear rate reduction was obtained with the internal liquid gallium coolant. Increasing the cutting speed to Vc = 900 m min−1, the data indicated a difference of 16% relative tool wear reduction with the internal liquid gallium. The results support the feasibility of using liquid gallium as an internal coolant in cutting inserts to effectively remove thermal energy.

show abstract

Indirect cooling of the cutting tool with a pumped two-phase system in turning of AISI 1045 steel

Cited by 14 publications

References 36 publications

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Magnetohydrodynamic-based Internal Cooling System for a Ceramic Cutting Tool: Concept Design, Numerical Study, and Experimental Validation

Sustainable Manufacturing Technologies: A Systematic Review of Latest Trends and Themes

Study on magnetohydrodynamic internal cooling mechanism within an aluminium oxide cutting tool

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